Note: Descriptions are shown in the official language in which they were submitted.
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DOWNHOLE RELEASE TOOL WITH INTEGRATED IGNITER
AND METHOD OF USING SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of US Provisional Application No.
63/195,551, the
entire contents of which is hereby incorporated by reference herein to the
extent not inconsistent
with the present disclosure. Applicant also filed US Provisional Application
Nos. 63/195,521;
63/195,540; and 63/222,578 on June 1, 2022, the entire contents of each of
which are hereby
incorporated by reference herein to the extent not inconsistent with the
present disclosure.
BACKGROUND
[0002] The present disclosure relates generally to oilfield technology. More
specifically, the
present disclosure relates to downhole tools and downhole activators.
[0003] Wellsite operations are performed to locate and access subsurface
targets, such as valuable
hydrocarbons. Drilling equipment is positioned at the surface and downhole
drilling tools are
advanced into the subsurface formation to form wellbores. Once drilled, casing
may be inserted
into the wellbore and cemented into place to complete the well. Once the well
is completed,
production tubing may be deployed through the casing and into the wellbore to
produce fluid to
the surface for capture.
[0004] During the wellsite operations, various downhole tools, may be deployed
into the earth to
perform various procedures, such as measurement, perforation, injection,
plugging, etc. Examples
of downhole tools are provided in US Patent/Application Nos. 10200024935;
10507433;
20200277837; 20170376775; 20170330947;20170576775; 20170530947; 20190242222;
20190234189; 10309199; 20190127290; 20190086189; 20190242209; 20180299239;
20180224260; 9915513; 20180038208; 9822618; 9605937; 20170074078; 9581422;
20170030693; 20160556132; 20160061572; 8960093; 2014003'3939; 8267012;
6520089;
20160115753; 20190178045; 10365079; 10844678; and 10365079, the entire
contents of which
are hereby incorporated by reference herein to the extent not inconsistent
with the present
disclosure. These downhole tools may be activated to perform the various
procedures. Example
procedures are provided in US Patent/Application Nos. 11,078,763; 10,858,919;
10,036,236;
10,365,079; 7,409,987; 6,431,269; 3,713,393; 3,024,843; 2022/0145732;
2004/0134667;
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20200072029; 20200048996; 20150345922; and 20160115753, the entire contents of
which are
hereby incorporated by reference herein to the extent not inconsistent with
the present disclosure.
[0005] Despite advancements in downhole technology, there remains a need for
efficient
techniques for reliably connecting, releasing, and/or activating downhole
tools, even in harsh
and/or compact downhole environments. The present disclosure is directed at
providing such
needs.
SUMMARY
[0006] In at least one aspect, the disclosure relates to a release tool for
releasing a downhole
portion a downhole tool, comprising a release housing, a top sub, a bottom
sub, a release assembly
and an integrated igniter. The release housing has a passage therethrough. The
top sub is positioned
at an uphole end of the release housing. The top sub is connected to an uphole
portion of the
downhole tool. The bottom sub is positioned at a downhole end of the release
housing. The bottom
sub is connected to the downhole portion of the downhole tool. The release
assembly is positioned
in the passage. The release assembly comprises a release mandrel and a locking
mechanism. the
release mandrel is operatively connected to the top sub and the bottom sub.
The locking mechanism
releasably secures the release assembly to the bottom sub. The integrated
igniter positioned in the
passage. The integrated igniter comprises an integrator housing, a switch
assembly, and an internal
propellant The switch assembly is operatively connected to the internal
propellant whereby, upon
triggering the switch, the internal propellant is ignited to release an
ignition fluid under ignition
pressure to unlock the locking mechanism and release the downhole portion of
the downhole tool
from the uphole portion of the downhole tool.
[0007] In another aspect, the disclosure relates to a downhole tool,
comprising: an uphole portion,
a downhole portion, and a release tool. The release tool comprising a release
housing, a top sub, a
bottom sub, a release assembly and an integrated igniter. The release housing
has a passage
therethrough. The top sub is positioned at an uphole end of the release
housing. The top sub is
connected to an uphole portion of the downhole tool. The bottom sub is
positioned at a downhole
end of the release housing. The bottom sub is connected to the downhole
portion of the downhole
tool. The release assembly is positioned in the passage. The release assembly
comprises a release
mandrel and a locking mechanism. the release mandrel is operatively connected
to the top sub and
the bottom sub. The locking mechanism releasably secures the release assembly
to the bottom sub.
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The integrated igniter positioned in the passage. The integrated igniter
comprises an integrator
housing, a switch assembly, and an internal propellant. The switch assembly is
operatively
connected to the internal propellant whereby, upon triggering the switch, the
internal propellant is
ignited to release an ignition fluid under ignition pressure to unlock the
locking mechanism and
release the downhole portion of the downhole tool from the uphole portion of
the downhole tool.
[0008] In another aspect, the disclosure relates to a method of releasing a
portion of a downhole
tool. The method comprises providing a release tool comprising a release
housing, a release
assembly, and an integrated ignitor, the release assembly and the integrated
ignitor positioned in
the release housing, connecting an uphole end of the release tool to an uphole
portion of the
downhole tool and a downhole end of the release tool to a downhole portion of
the downhole tool;
and selectively releasing the downhole portion of the downhole tool by
triggering the integrated
ignitor to release a fluid under pressure to unlock the release assembly such
that the downhole
portion of the downhole tool is released from the uphole portion of the
downhole tool.
[0009] In at least one aspect, the disclosure relates to a release tool for
releasing a portion a
downhole tool. The release tool comprises a release housing; an integrated
igniter; and a release
assembly.
[0010] In another aspect, the disclosure relates to a downhole tool. The
downhole tool comprises
an uphole portion; a downhole portion; and a release tool connected to the
uphole portion and
releasably connected to the downhole portion.
[0011] In yet another aspect, the disclosure relates to a method of activating
a release tool of a
downhole tool. The method comprises positioning an integrated igniter into a
release tool;
positioning the release tool about the downhole tool; positioning the downhole
tool in a wellbore;
and triggering the integrated igniter to ignite a propellant in the release
tool.
[0012] Finally, in another aspect, the disclosure relates to a method of
releasing a portion of a
downhole tool. The method comprises providing a release tool; connecting the
release tool
between an uphole and a downhole portion of the downhole tool; positioning the
downhole tool in
a wellbore; and releasing the downhole portion of the downhole tool by
activating the release tool
with the integrated igniter.
[0013] In at least one aspect, the present disclosure also relates to an
igniter for activating a
downhole component of a downhole tool. The igniter comprises an igniter
housing; a switch
assembly; and a propellant. The switch assembly may comprise a single or dual
switch. The
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propellant may be positioned outside of or within the igniter housing.
[0014] In another aspect, the present disclosure relates to a downhole tool
comprising a downhole
component, and an igniter for activating the downhole component. The igniter
comprises an igniter
housing; a switch assembly; and a propellant The igniter may be an integrated
igniter positioned
within the downhole component, or a remote igniter positioned outside the
downhole component.
[0015] The downhole tool may be a setting tool. The setting tool may be
activated by inserting the
igniter into the setting tool; deploying the setting tool with the integrated
igniter into the wellbore;
triggering the integrated igniter by passing a trigger signal from a surface
unit to the switch
assembly such that the switch assembly ignites the propellant to release a gas
into the setting tool
with sufficient force to advance a piston in the setting tool and deploy a
plug assembly.
[0016] Finally, in another aspect, the disclosure relates to a method of
activating a downhole
component of a downhole tool, such as a release tool, a setting tool, or other
downhole component.
The method comprises positioning the igniter about the downhole tool;
positioning the downhole
tool in the wellbore; and triggering the igniter.
[0017] This Summary is not intended to be limiting and should be read in light
of the entire
disclosure including text, claims and figures herein.
BRIEF DESCRIPTION OF TIM DRAWINGS
[0018] So that the above recited features and advantages of the present
disclosure can be
understood in detail, a more particular description of the invention, briefly
summarized above,
may be had by reference to the embodiments thereof that are illustrated in the
appended drawings.
The appended drawings illustrate example embodiments and are, therefore, not
to be considered
limiting of its scope. The figures are not necessarily to scale and certain
features, and certain views
of the figures may be shown exaggerated in scale or in schematic in the
interest of clarity and
conciseness.
[0019] Figure 1 is a schematic view of a wellsite with surface and downhole
equipment, the
downhole equipment comprising a downhole tool including a release tool with an
integrated
igniter.
[0020] Figures 2A and 2B show side and cross-sectional views, respectively, of
the release tool.
[0021] Figures 3A and 3B show exploded views of the release tool.
[0022] Figures 4A and 4B are cross-sectional views of the release tool before
and after activation
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by the integrated igniter.
[0023] Figures 5A and 5B are partial, cross-sectional views of the release
tool with a locking
sleeve in a locked position.
[0024] Figures 6A and 6B are partial, cross-sectional views of the release
tool with the locking
sleeve in an unlocked position.
[0025] Figures 7A ¨ 7D are cross-sectional views showing an activation
sequence of the release
tool.
[0026] Figures 7E and 7F are exploded and cross-sectional views, respectively,
of another version
of the release tool.
[0027] Figures 8A ¨ 8C are hidden, partial cross-sectional, and exploded
views, respectively, of
the integrated igniter with a single switch assembly.
[0028] Figures 9A and 9B are partial cross-sectional and exploded views,
respectively, of the
integrated igniter with a dual switch assembly.
[0029] Figures 10A ¨ 10C are hidden, cross-sectional, and exploded views,
respectively, of a
locking version of the integrated igniter with a single switch assembly and an
external propellant.
[0030] Figures 11A and 11B are flow charts depicting a method of releasing a
portion of a
downhole tool and a method of activating a downhole component, respectively.
DETAILED DESCRIPTION
[0031] The description that follows includes exemplary apparatus, methods,
techniques, and/or
instruction sequences that embody techniques of the present subject matter.
However, it is
understood that the described embodiments may be practiced without these
specific details.
[0032] This disclosure relates to a release tool for releasing a portion of a
downhole tool
positionable in a wellbore at a wellsite. The release tool may include an
integrated activator and a
release assembly therein. The integrated activator may be an integrated
igniter triggered to activate
(e.g., shift, alter, drive, deploy, move, etc.) the release tool to release a
downhole portion of the
downhole tool into the wellbore. For example, the integrated igniter may be
triggered from the
surface to ignite a propellant within the release tool which activates the
release tool to detach the
downhole portion of the downhole tool in the wellbore.
[0033] The release tool may be a downhole component used to release a downhole
portion of the
downhole tool including one or more other downhole components. The combination
of multiple
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downhole components formed into one assembly (e.g., a tool string) is referred
to as a downhole
tool.' The downhole tool may be a modular assembly including various
combinations of multiple
downhole components, such as a cable release, a collar locator, weight bars, a
perforating tool
(gun), a release tool, a setting tool, a plugging tool, an electronics hub,
etc. One or more downhole
components may be included in a single housing, or in separate housings of the
downhole tool.
The downhole components may be operatively (e.g., electrically and/or
mechanically) connected
together. One or more of the downhole components may operate separately or in
concert.
[0034] The release tool may include a locking mechanism for selectively
detaching a portion of
the downhole tool, for example, during stuck in hole situations, maintenance,
assembly, etc. The
integrated igniter may be triggered to shift the locking mechanism (e.g., a
sliding (release) sleeve
and ball bearings (release balls)) from a locked to an unlocked position. In
the unlocked position,
an uphole portion of the downhole tool may be retrievable to the surface while
a downhole portion
of the downhole tool is free to fall into the wellbore.
[0035] The integrated igniter may be positioned within (e.g., integrated into)
the release tool to
enable pre-assembly of the release tool with the integrated activator therein,
to enable quick
connection/disconnection of downhole components connected downhole from the
release tool, to
provide a release tool usable with various combinations of various types of
downhole
tools/components, to provide a compact structure for use in restricted
downhole spaces, etc. The
release tool may also be provided with various configurations, such as various
types of igniters or
other activators (e.g., a single use, dual use, etc.) and various
configurations of propellants (e.g.,
internal or external to the igniter, disc shaped, cylindrically shaped, etc.).
The integrated igniter
may also be removably positioned within the release tool to enable repair,
replacement, and/or
reuse of various integrated activators (igniters). The integrated igniter may
be replaced with the
same integrated igniter, or another type of integrated activator. This
configuration may be used to
provide a unitary release tool (with the integrated igniter pre-assembled
therein) connectable to the
downhole tool for use therewith.
[0036] The present disclosure seeks to provide one or more of the following
features, among
others: interchangeability with various tools, reduction in downtime,
reduction in lost equipment,
ability to remove portions of equipment, ability to preserve the integrity of!
prevent damage to a
conveyance (e.g., wireline), reliability, ballistic activation, operability in
harsh downhole
conditions, ease of manufacture and assembly, ability to couple to or
integrate with existing
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components, operability with components of other tools for use therewith,
reduction in cost,
increased efficiency, elimination of redundant components, flexibility of use,
ability to change
configurations to match operational needs, ability to provide one or more
activations, time savings,
efficient operation, low maintenance costs, compact design, replaceable and/or
disposable
components, etc.
[0037] Figure 1 is a schematic view of a wellsite 100 with surface equipment
102a and downhole
equipment 102b, the downhole equipment 102b comprising a downhole tool 101
including a
release tool 103 with an integrated igniter 105. The surface equipment 102a
and the downhole
equipment 102b are positioned about a wellbore 104 at the wellsite 100. The
wellsite 100 may be
any wellsite positioned about a subterranean formation, such as an
unconventional formation (e.g.,
shale) with a reservoir (e.g., oil, gas, water, etc.) therein.
[0038] The surface equipment 102a includes a conveyance reel 106, and a
surface unit 108. The
surface equipment 102a may include a wellhead 107 (and other surface
components) positioned
about the top of the wellbore 104. The conveyance reel 106 may be a spool
rotationally mounted
at the surface. The conveyance reel 106 supports a conveyance 110 as it is
deployed into the
wellbore 104. A pulley 112 may optionally be provided to support the
conveyance 110 about the
wellbore 104 as schematically shown. In the example of Figure 1, the
conveyance 110 is a wireline
cable electrically and communicatively coupled between the surface unit 108
and the downhole
tool 101 for passing signals therebetween.
[0039] The downhole equipment 102b comprises the downhole tool 101 positioned
in the wellbore
104 and supported therein by the conveyance 110. The wellbore 104 may have a
casing 114 therein
to line a surface of the wellbore 104. The downhole tool 101 may be deployed
through the casing
and into an open portion of the wellbore 104 via the conveyance 110 for
performing downhole
operations. The downhole tool 101 is provided with various downhole components
116 for
performing such downhole operations.
[0040] Figure 1 shows an example configuration of the downhole tool 101. In
this example, the
downhole tool 101 includes several downhole components 116 connected together
to form a tool
string. The downhole components 116 in this example include a cable head 116a,
weight bars
116b, a collar locator 116c, a perforating tool 116d, a release tool 103, a
setting tool 116e, and a
plug assembly 116f. Various arrangements of one or more of the downhole
components 116a-f
(and/or other downhole components 116, such as electronics sub (not shown))
may be provided.
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[0041] The downhole components 116 as shown are used to perform various
downhole operations.
The cable head 116a may operatively connect the downhole tool 101 to the
conveyance 110. The
weight bars 116b may be provided to add weight to the downhole tool 101. The
collar locator 116c
may be used to locate portions of the casing 114, or other items along the
wellbore 104. As
schematically shown, the perforating tool 116d may be used to launch shaped
charges to form
perforations 109 along the wall of the wellbore 104. Examples of perforating
tools are provided in
US Patent/Application Nos. 10,036,236; 20200072029; and 20200048996,
previously
incorporated herein.
[0042] The setting tool 116e may be coupled to the plug assembly 116f for use
therewith. The
setting tool 116e may be activated to deploy a plug from the plug assembly
116f (as indicated by
the double arrow) to anchor the downhole tool 101 along the wellbore 104.
Examples of techniques
for setting and plugging are described in US Patent Application No.
20190242209; 10365079;
10844678; and 3,024,843, previously incorporated by reference herein.
[0043] The release tool 103 includes a release housing 115, a release assembly
117, and the
integrated igniter 105. The release tool 103 may be activated by the
integrated igniter 105 to
perform a release operation to detach a downhole portion 101b of the downhole
tool 101 as is
described further herein. In the example shown in Figure 1, the release tool
103 is positioned
between the perforating tool 116d and the setting tool 116e. The release tool
103 is activated by
the integrated igniter 105 to selectively release and detach the setting tool
116e and the plug
assembly 116f into the wellbore 104.
[0044] The release tool 103 may be used with various configurations of the
downhole tool 101 for
releasing various of the downhole components 116. One or more release tools
103 and/or
integrated igniters 105 (or other integrated activators) may be positioned in
various locations about
the downhole tool 101 for releasing one or more portions of the downhole tool
101 (e.g., the
downhole portion 101b) into the wellbore 104. An uphole portion 101a of the
downhole tool 101
may remain intact and suspended from the conveyance 110 upon release.
Additional integrated (or
other) igniters may also be positioned in other downhole components 116 for
activation thereof.
[0045] The release tool 103 and/or the integrated igniter 105 may be
communicatively coupled by
a communication link 118 to the surface to receive signals therefrom. In the
example shown in
Figure 1, the communication link 118 extends from the surface unit 108 and to
the downhole tool
101 via the conveyance 110. The communication link 118 extends through the
downhole
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components 116 and to the integrated igniter 105. The communication link 118
also extends
through the release tool 103 to the setting tool 116e and/or the plug assembly
116f. The surface
unit 108 may be provided with personnel (e.g., operators) and/or electronics
(e.g., central
processing units (CPUs), controllers, etc.) for sending trigger signals via
the communication link
118 to the integrated igniter 105.
[0046] While Figure 1 shows a certain configuration of the wellsite 100, the
surface equipment
102a, and the downhole equipment 102b, various configurations may be used. For
example, one
or more communication links 118, surface units 108, and/or other devices may
be provided for
triggering the integrated igniter 105 and activating the release tool 103. In
another example, the
downhole tool 101 may have one or more downhole components 116 in use with one
or more
release tools 103 and/or integrated igniters 105. Additionally, while not
shown, it will be
appreciated that the release tool 103 could also be coupled to other downhole
components 116
and/or portions of the downhole tool 101 for release into the wellbore 104
(Figure 1). It will also
be appreciated that, while the descriptions herein refer to certain uphole and
downhole positions,
such positions may optionally be reversed.
[0047] Figures 2A ¨ 2B and 3A ¨ 3B show various views of the release tool 103.
Figures 2A and
2B show side and cross-sectional views, respectively, of the release tool 103.
Figures 3A and 3B
show exploded views of the release tool 103. These figures show example
configurations of the
release tool 103 with the integrated igniter 105. As shown in these figures,
the integrated igniter
105 is integrated into the release tool 103 for ballistic activation of the
release tool 103 to perform
a release operation. This configuration may be used to provide a unitary
release tool 103 capable
of releasing the downhole portion 101b of the downhole tool 101, such as the
setting tool 116e and
the plug assembly 116f (and/or other downhole component(s) 116) (Figure 1).
[0048] As also shown in Figure 2A ¨ 3B, the release tool 103 includes the
release housing 115,
the release assembly 117, and the integrated igniter 105. The release housing
115 is a tubular metal
member with a passage 211 therethrough. In the example shown, a top sub 215a
is positioned in
an uphole end of the release housing 115 and a bottom sub 215b is positioned
in a downhole end
of the release housing 115.
[0049] The top sub 215a may extend into and threadedly connect to an uphole
end of the release
housing 115. The bottom sub 215b may extend into a downhole end of the release
housing 115.
The top and bottom subs 215a,b may also connect to an adjacent downhole
component 116, such
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as the perforating tool 116d and the setting tool 116e (Figure 1),
respectively. In the example
shown in Figures 2A and 2B, the bottom sub 215b is connected to another top
sub 215a of an
adjacent downhole component 116. The top and bottom subs 215a,b may be
electrical connectors
and/or support electrical components capable of passing signals to the
adjacent downhole
components 116 as described further herein.
[0050] The release assembly 117 and the integrated igniter 105 are positioned
in the release
housing 115 between the top sub 215a and the bottom sub 215b. The release
assembly 117 is
positioned between the integrated igniter 105 and the bottom sub 215b. The
release assembly 117
includes a release mandrel 219a, a feedthru 219b, a locking sleeve 219c, and
locking balls 219d.
The release mandrel 219a has an uphole end shaped for connection within the
release housing 115
and a downhole end shaped for receivingly connecting to the bottom sub 215b.
[0051] The release mandrel 219a is a tubular member positionable in the
release housing 115 to
support an electrical coupling 221a and a locking mechanism 221b therein. The
electrical coupling
221a is provided by the feedthru 219b. The feedthru 219b is an elongate member
with a stepped
outer surface that extends into an uphole end of the release mandrel 219a. The
feedthru 219b may
be an electrical contact shaped for electrical contact with the integrated
igniter 105 at one end and
the bottom sub 215b at an opposite end.
[0052] A retainer spring 219e, a disk spring 219f, and a ball catch 219g may
be positioned between
the feedthru 219b and the release mandrel 219a to support the feedthru 219b in
the release mandrel
219a. The ball catch 219g may be a tubular member slidably positioned within
the uphole end of
the release mandrel 219a and may be shaped to receive and support the feedthru
219b therein. The
retainer spring 219e may be a ring-shaped spring positioned between the
feedthru 219b and the
release mandrel 219a to cushion the feedthru 219b about the release mandrel
219a. The disk spring
219f may be a wave-shaped spring positioned between the feedthru 219b and the
release mandrel
219a to retain the ball catch 219g about the release mandrel 219a.
[0053] In the example shown in Figures 2B and 3B, the locking mechanism 221b
includes the
locking sleeve 219c and the locking balls 219d. The locking sleeve 219c and
the locking balls
219d are movable members movably positioned between a downhole end of the
release mandrel
219a and the release housing 115. The locking sleeve 219c is a tubular member
slidably movable
along an outer periphery of the release mandrel 219a and along an inner
surface of the release
housing 115. The locking sleeve 219c has a tapered downhole end that defines
an angled ball
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surface 223a. The ball surface 223a is angled away from the downhole end of
the release mandrel
219a. A disk spring 219h may be positioned between the locking sleeve 219c and
the release
mandrel 219a to cushion movement of the locking sleeve 219c.
[0054] The locking balls 219d are movably positionable about the locking
sleeve 219c, the release
mandrel 219a, and the bottom sub 215b in response to movement of the locking
sleeve 219c. Seven
locking balls 219d are shown, but any number may be provided. The release
mandrel 219a has ball
receptacles (holes) 223c radially disposed about a downhole end of the release
mandrel 219a. The
bottom sub 215b has ball seats (depressions) 223b shaped to receive the
locking balls 219d. In a
locked position, the locking balls 219d are seated in the ball seats 223b,
extend through the ball
receptacles 223c, and contact the locking sleeve 219c. Upon the uphole
movement of the locking
sleeve 219c, the locking balls 219d move radially away from the ball seats
223b, through the ball
receptacles 223c, and against the ball surface 223a of the locking sleeve
219c. In the unlocked
position, the locking balls 219d are no longer wedged into the ball seats
223b, thereby freeing the
bottom sub 215b as is described further herein.
[0055] The integrated igniter 105 is receivably positioned in the release
housing 115 between the
release assembly 117 and the top sub 215a. The integrated igniter 105 is
electrically connected to
the top sub 215a. The top sub 215a is electrically connected to the other
downhole components
116a-d and the conveyance 110, thereby forming part of the communication link
118 (Figure 1).
An electrical pathway may be defined by the communication link 118 for sending
a trigger signal
from the surface unit 108, through the downhole components 116a-d, to the top
sub 215a, and to
the integrated igniter 105. The integrated igniter 105 is electrically
connected to the electrical
coupling 221a (and/or the feedthru 219b) which is connected to the bottom sub
215b, thereby
extending the communication link 118 through the release tool 103 and to the
other downhole
components 116e,f. Examples of igniters that may be used as the integrated
igniter 105 are
described further herein.
[0056] The integrated igniter 105 is activatable by the trigger signal to
ignite a propellant 220,
thereby releasing pressurized fluid (e.g., gas) through the ball catch 219g
and into a pressure
chamber 222 defined between the bottom sub 215b and the locking sleeve 219c.
The release
mandrel 219a may have holes 224 about an uphole end of the bottom sub 215b for
passing fluid
from the ball catch 219g through the holes 224 and into the pressure chamber
222. This fluid has
a pressure used to activate the release assembly 117 to shift the locking
mechanism 221b (e.g., the
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locking sleeve 219c and the locking balls 219d) from the locked to the
unlocked position as is
described further herein.
[0057] While specific configurations of the release tool 103 and the
integrated igniter 105
integrated therewith are shown, it will be appreciated that various
configurations of the integrated
igniter 105 and the release tool 103 may be provided. For example, one or more
components of
the release tool 103 and/or the integrated igniter 105 and various shapes of
components can be
provided.
[0058] Figures 4A ¨ 6B show various views of activation of the release tool
103. Figures 4A and
4B are cross-sectional views of the release tool 103 before and after
activation by the integrated
igniter 105. Figures 5A and 5B are partial, cross-sectional views of the
release tool 103 with the
locking sleeve 219c in the locked position. Figure 5B is a detailed view of a
portion 5B of Figure
5A. Figures 6A and 6B are partial, cross-sectional views of the release tool
103 with the locking
sleeve 219c in the locked position. Figure 6B is a detailed view of a portion
6B of Figure 6A. As
shown by these views, the integrated igniter 105 may be triggered to activate
the release tool 103
to release the downhole portion 101b of the downhole tool 101 (Figure 1).
[0059] As shown by Figures 4A ¨ 6B, the trigger signal is an electrical
current passed via the
communication link 118 through the top sub 215a and to the integrated igniter
105. The integrated
igniter 105 is triggered by the trigger signal to ignite the propellant 220
and release a pressurized
fluid through the feedthru 219b and into the pressure chamber 222 as shown in
Figure 4A. The
pressurized gas applies a force against the locking sleeve 219c and drives the
locking sleeve 219c
from the locked position of Figure 4A, 5A, and 5B to the unlocked position of
Figure 4B, 6A, and
6B.
[0060] As shown in Figures 4B, after the locking sleeve 219c moves to the
unlocked position, the
locking balls 219d move from the locked (seated) position in the ball seats
223b of the release
mandrel 219a to the unlocked (unseated) position against the ball surface 223a
of the locking
sleeve 219c. In this unlocked position, the locking balls 219d are no longer
seated in the ball seats
223b of the bottom sub 215b.
[0061] As shown in Figures 4B, 6A, and 6B, with the locking balls 219d
unseated, an uphole end
of the bottom sub 215b is free to slidingly move out of the release mandrel
219a and the release
housing 115. The ball catch 219g slidingly moves downhole with the bottom sub
215b and then
retracts by force of the disk spring 219f as the bottom sub 215b releases from
the release housing
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115. The bottom sub 215b is now detached from the rest of the release tool
103. The bottom sub
215b and the downhole portion 101b attached to the bottom sub 215b are also
free to fall away
from the uphole portion 101a (Figure 1). The uphole portion 101a my
retrievable to the surface by
the conveyance 110 (Figure 1). With the downhole portion 101b detached, the
uphole portion 101a
may be more easily retrieved, particularly if the downhole portion 101b is
stuck in the wellbore
104 (Figure 1).
[0062] Figures 7A ¨ 7C are cross-sectional views showing an activation
sequence of the release
tool 103. Figure 7A shows the release tool 103 in a pre-activation position
with the integrated
igniter 105 positioned therein before triggering. The locking sleeve 219c
remains in its downward
and locked position, and the bottom sub 215b is locked within the release
housing 115 by the
locking balls 219d.
[0063] Figure 7B shows the release tool 103 after a trigger signal is sent
from the surface to the
integrated igniter 105 and the integrated igniter 105 is triggered to ignite
the propellant 220 (Figure
2B) and pressure is released into the chamber 222. This pressure has driven
the locking sleeve
219c uphole to the unlocked position as indicated by the upward arrow.
[0064] Figure 7C shows the movement of the locking balls 219d after the
locking sleeve 219c has
shifted to the unlocked position. This movement of the locking sleeve 219c has
allowed the locking
balls 219d to move radially from the ball seats 223b of the bottom sub 215b
through the ball
receptacles 223c and against the ball surface 223a of the locking sleeve 219c.
[0065] Figure 7D shows detachment of the bottom sub 215b after movement of the
locking balls
219d to the unlocked position. The bottom sub 215b is no longer retained by
the locking balls 219d
and is now free to move away from the release mandrel 219a and to slide out of
the release housing
115. Once the bottom sub 215b has detached, the downhole portion 10 lb
connected to the bottom
sub 215b may be released from the uphole portion 101a of the downhole tool 101
(Figure 1).
[0066] Figures 7E and 7F are exploded and cross-sectional views, respectively,
of another version
of the release tool 703. As shown in these views, the release tool 703 may be
provided with various
components to facilitate operation. As shown in Figure 7E, the release tool
703 includes the top
sub 215a, the bottom sub 215b and the release housing 115 as described herein
for the release tool
103 (see, e.g., Figures 3A and 3B). In this version, the release tool 703 also
includes a release
housing nut 721a, a retainer ring 721b, a sub feedthnt 721c, and a different
release assembly 717.
[0067] The release housing nut 721a may be a tubular member concentrically
positioned between
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the release housing 115 and the ignitor 105. The release housing nut may be
provided to
receivingly support the ignitor 105 therein and define a chamber for passing
fluid (e.g., gas) from
the ignitor 105 when ignited. The retainer ring 721b may be a circular member
positioned about
an end of the release housing nut 721 and the top sub 215a. The sub feedthru
721c may be an
electrical connector positionable in the bottom sub 215a and electrically
connectable to portions
of the release tool 703 and an adjacent downhole component connected to the
bottom sub 215b for
passing signals therebetween.
[0068] The release assembly 717 includes a release mandrel (housing) 719a, a
feedthru 719b, a
locking (release) sleeve 719c, and locking balls 219d. The locking balls 219d
may be the same as
those described herein. The release mandrel 719a, feedthru 719b, and locking
sleeve 719c may be
similar to the release mandrel 219a, feedthru 219b, and locking sleeve 219c as
described herein,
except with different shapes. Springs 719f and 719h may be similar to springs
219f and 219h as
described herein, except with different shapes.
[0069] The release assembly 717 also includes a sleeve 719i, a cap 719j, and
pins 719k. The sleeve
719i may be shaped to support the feedthru 719b about the internal end of the
bottom sub 215b.
The cap 719j may be secured about an internal end of the bottom sub 215b. The
pins 719k may be
retaining pins for securing the release mandrel 719a within the release tool
703.
[0070] In operation, the release assembly 717 performs the same functions as
the release assembly
117 described herein. In this case, with the release assembly 717, electrical
current is passed
through the top sub 215a to trigger the switch assembly of the ignitor to
ignitor the propellant. The
propellant releases a pressurized gas into the release tool 103. This pressure
is passed through the
holes in the insulated feedthru 719b. This causes the small internal piston
7191 to shift. After the
small piston has shifted, the retainer pins 719k move inward allowing the
sleeve 719i to shift. This
allows the ball bearings 219d to move freely and shift, thereby allowing the
fishing neck to release
from the release assembly 717. This unlocks the release assembly 717 and
allows the downhole
portion 101b to release from the uphole portion 101a.
[0071] Figures 8A ¨ 10C show various versions of the igniter 805, 905, and
1005. Any of these
versions of the igniter 805, 905, 1005 may be used as the integrated igniter
105 as described herein.
Figures 8A - 8C show a single contact version of the igniter 805, and Figures
9A ¨ 9C show a dual
contact version of the igniter 905. These versions have the propellant 119 in
an internal position.
These versions also may not require a locking or screw or support about the
propellant 119.
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[0072] Figures 8A ¨ 8C are hidden, partial cross-sectional, and exploded
views, respectively, of
the igniter 805 with a single switch assembly 834. In this version, the
igniter 805 includes an igniter
housing 832, the switch assembly 834, and the propellant 119. The igniter
housing 832 includes a
bulkhead (or uphole connector) 854a, igniter portions 854b, and a nose cone
854c The igniter
housing 832 may be shaped for insertion into the release housing 115 of the
release tool 103 (see,
e.g., Figures 2B and 4A ¨ 4B).
[0073] The bulkhead 854a is a cylindrical member with threads thereon for
threaded connection
to the downhole component 116 (e.g., the perforating tool 116d of Figure 1).
The nose cone 854c
is a tapered member with a passage for extension of the propellant 119
therethrough. The igniter
portions 854b are curved portions that form a tubular member when joined
together. The igniter
portions 854b are attached to the bulkhead 854a at one end and the nose cone
854c at an opposite
end to form a switch chamber 855 for receiving the switch assembly 834
therein. The nose cone
854c may be shaped for easy removal and for easy access to the propellant 119
to facilitate
replacement of the propellant 119 after use or as needed, and/or to facilitate
access into the igniter
805.
[0074] The switch assembly 834 is supported within the igniter housing 832.
The switch assembly
834 includes an insulator 856a, a plunger 856b, a plunger plug 856c, a single
igniter plug 856d,
wires 856e, and a single addressable switch 856f. The insulator 856a is a
tubular, spring-loaded
member connected to the bulkhead 854a. The insulator 856a is made of a non-
conductive material
to prevent electrical contact between the bulkhead 854a and the switch
assembly 834. The plunger
856b is positioned in the insulator 856a and extends therefrom for connection
to the plunger plug
856c.
[0075] The plunger 856b may be an electrical connector for connecting the
switch assembly 834
to other portions of the downhole tool 101 for communication therewith. For
example, the plunger
856b may extend through the bulkhead 854a for electrical connection to the
perforating tool 116d
(Figure 1), and/or to the communication link 118. The wires 856e may be
electrically connected
to other downhole components 116, the communication link 118, the conveyance
110, the surface
unit 108, etc. (Figure 1). In this manner, the switch assembly 834 may be
electrically connected to
the surface for receipt of a trigger signal.
[0076] The plunger plug 856c is an electrical connector supported in the
igniter 805. The plunger
plug 856c is electrically connectable to the plunger 856b at one end, and to
the single igniter plug
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856d by the wires 856e at the other end. The wires 856e may include a ground
wire 856e1 and a
surface link wire 856e2. The ground wire 856e1 may be coupled to the bulkhead
854a. The surface
link wire 856e2 is electrically connected to the plunger 856b.
[0077] The single igniter plug 856d is an electrical connector supported in
the igniter 805. The
single igniter plug 856d is electrically connected to the addressable switch
856f by a plug contact
858b. In this version, the addressable switch 856f is a single switch and the
plug contact 858 is a
single contact. The single addressable switch 856f is electrically connected
with the surface unit
108 via the single igniter plug 856d, the wires 856e, and the plunger 856b
(which is in
communication with the surface unit 108 as described herein).
[0078] The single addressable switch 856f is also electrically connected with
the propellant 119
via the plug contact 858. The propellant 119 is also positioned within the
igniter housing 832. The
propellant 119 is shown as a tubular member supported within the nose cone
854c and extendable
therethrough. The propellant 119 may include one or more individual power
packs of combustible
material ignitable by an electrical charge applied by the addressable switch
856f. The single
addressable switch 856f may be used for a single ignition of the integrated
igniter 805.
[0079] Figures 9A and 9B are partial cross-sectional and exploded views,
respectively, of the
igniter 905 with a dual switch assembly 934. This version is similar to the
igniter 805 of Figures
8A ¨ 8C with the same igniter housing 832 (with bulkhead 854a, igniter
portions 854b, and nose
cone 854c), without an insulator 856a, and with a different switch assembly
934.
[0080] In this version, the dual switch assembly 934 includes the same plunger
856b, and wires
856e (as shown in Figures 8A-8C). This switch assembly 934 also includes a
switch housing 859,
an o-ring 860a, compression spring 860b, plunger plug 856c, a dual igniter
plug 856d, and a dual
addressable switch 856f. The plunger plug 856c includes a plunger plate 858a
and dual plug
contacts 858b. The o-ring 860a is positioned between the bulkhead 854a and the
igniter portions
854b. The plunger 856b is supported in the bulkhead 854a by the compression
spring 860b. The
compression spring 860b is positioned within the bulkhead 854a between the
plunger 856b and
the plunger plug 856c.
[0081] The plunger plug 856c is an insulated feed thru supported in the
igniter portions 854b. The
switch housing 859, the plunger plug 856c, the dual igniter plug 856d, and the
wires 858e may
also supported in the igniter portions 854b. This switch housing 859 may
enclose and/or support
one or more components of the switch assembly 934 (e.g., plugs 854c,d and
wires 856e) for easy
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removal and replacement after use or as needed.
[0082] The plunger plug 856c electrically connects the plunger 856b to the
dual igniter plug 856d.
The dual igniter plug 856d is electrically connected to the dual plug contact
858b and to the dual
addressable switch 856f. The dual addressable switch 856f is connected to the
propellant 119 by
the dual plug contacts 858b. The addressable switch 856f has dual contacts
858b for redundant
contact with the propellant 119. The dual addressable switch 856f may be used
for a dual ignition
of the integrated igniter 805. As demonstrated by this example, one or more
contacts 858b, 858b
may be used to provide redundant electrical connection with the propellant 119
to further assure
ignition.
[0083] Figures 10A ¨ 10C are hidden, cross-sectional, and exploded views,
respectively, of a
locking (e.g., screw on) version of the igniter 1005 with the single switch
assembly 1034 and an
external propellant 119. This version has the propellant 119 in an external
position outside of the
igniter housing 1052.
[0084] Like the integrated igniters 805 of Figures 8A ¨ 8C and 905 of Figures
9A and 9B, this
version includes an igniter housing 1052, the switch assembly 1034, and the
external propellant
119. In this version, the igniter housing 1052 is a cylindrical member with
the propellant 119
external thereto. A demonstrated by this version, the igniter housing 1052 may
have different
shapes, and may support the propellant 119 external from other components
housed within the
igniter housing 1052.
[0085] In this version, the igniter housing 1052 includes a bulkhead 1054a and
igniter portions
1054b. The igniter portions 1054b are similar to the igniter portions 854b of
Figures 8A ¨ 8C. An
o-ring 1060a is positionable about the bulkhead 1054a. The bulkhead 1054a
operates similar to
the bulkheads 854a of Figures 8A ¨ 8C for communication via communication link
118 (Figure
1).
[0086] The switch assembly 1034 is positioned within the igniter portions
1054b, and includes the
same addressable switch 856f, single contact 858, and wires 856e of the switch
assembly 834 of
Figures 8A - 8C. This switch assembly 1034 also includes a bulkhead feedthru
1062a and a nose
feedthru 1062b. The bulkhead feedthru 1062a is extendable through the bulkhead
1054a. The wires
856e are electrically connectable to the bulkhead feedthru 1062a at one end
and the single contact
858 at the other end. The single contact 858 is connectable to the nose
feedthru 1062b. The
bulkhead feedthru 1062a extends through the bulkhead 1054a for connection to
the wires 856e at
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one end and to another downhole component, such as the perforating tool 116d
for communication
with the conveyance 110 and the surface unit 108 (Figure 1).
[0087] This version may also employ locking means (e.g., a locking or screw or
support) about
the external propellant 119 This version is provided with a locking ring 1064
positioned at a
downhole end of the igniter portions 1054b. The propellant 119 is secured to
the housing 1052 by
the locking ring 1064, and extends from an end of the igniter housing 1052 for
insertion into the
downhole tool (e.g., into the passage 211 of the release tool 103 (e.g.,
Figure 2B)).
[0088] The locking ring 1064 may be used to secure the propellant 119 to the
igniter 1005. The
locking ring 1064 is a ring-shaped member including a housing portion 1066a
and a nose portion
1066b extending downhole therefrom. The housing portion 1066a may be threaded
for connection
to the igniter portions 1054b. The housing portion 1066a may also have a hole
to receive the nose
feedthru 1062b therethrough.
[0089] The nose feedthru 1062b extends into the nose portion 1066b for
connection to the switch
assembly 1034. The nose portion 1066b has a nose receptacle 1068 for
receivingly supporting the
propellant 119 therein. Upon triggering of the switch assembly 1034, a signal
passes from the
switch assembly 1034 via the nose feedthru 1062b to ignite the propellant 119,
thereby activating
the downhole component (e.g., activating release tool 103 to detach the
downhole portion 101b of
the downhole tool 101 (Figure 1)).
[0090] While specific configurations of the release tool and the integrated
igniter integrated
therewith are shown, it will be appreciated that various configurations of the
integrated igniter and
the release tool may be provided. It will also be appreciated that each of the
igniters described
herein may include one or more features of the other igniters described
herein. For example, one
or more wires, connectors, contacts, propellants, portions of housings, shapes
of components, etc.
can be provided.
[0091] Figures 11A and 11B are flow charts depicting a method 1100a of
releasing a portion of a
downhole tool and a method 1100b of activating a downhole component,
respectively. The method
1100a involves 1180 - providing a release tool. The release tool may comprise
a release housing;
an integrated igniter; and a release assembly. The release assembly may
comprise a locking sleeve,
a release mandrel, and locking balls. The method 1100a further involves 1181 -
connecting the
release tool between an uphole portion and a downhole portion of the downhole
tool. This
connecting may involve connecting an uphole end of the release tool to the
uphole portion of the
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downhole tool; and connecting a downhole end of the release tool to the
downhole portion of the
downhole tool. The method 1100a further involves 1182 - positioning the
downhole tool in a
wellbore and 1183 - releasing the downhole portion of the downhole tool by
activating the release
tool with the integrated igniter.
[0092] The method 1100b involves 1180 - positioning an integrated igniter into
a release tool. The
method 1100b further involves 1182 - positioning the release tool about the
downhole tool, 1184
- positioning the downhole tool in a wellbore, and 1188 - triggering the
integrated igniter to ignite
a propellant in the release tool. The method 1100b may further involve 1190 -
replacing the
propellant and portions of the integrated igniter and 1192 - repeating the
method 1100b.
[0093] Part or all of the methods 1100a,b may be performed in various orders,
and part or all may
be repeated.
[0094] While the embodiments are described with reference to various
implementations and
exploitations, it will be understood that these embodiments are illustrative
and that the scope of
the inventive subject matter is not limited to them. Many variations,
modifications, additions and
improvements are possible. For example, various combinations of one or more of
the features
and/or methods provided herein may be used.
[0095] Plural instances may be provided for components, operations or
structures described herein
as a single instance. In general, structures and functionality presented as
separate components in
the exemplary configurations may be implemented as a combined structure or
component.
Similarly, structures and functionality presented as a single component may be
implemented as
separate components. These and other variations, modifications, additions, and
improvements
may fall within the scope of the inventive subject matter. For example, while
certain tools and
components are provided herein, it will be appreciated that various
configurations (e.g., shape,
order, orientation, etc.) of the tools and components herein may be used.
While the figures herein
depict a specific configuration or orientation, these may vary. First and
second are not intended
to limit the number or order.
[0096] Insofar as the description above and the accompanying drawings disclose
any additional
subject matter that is not within the scope of the claim(s) herein, the
inventions are not dedicated
to the public and the right to file one or more applications to claim such
additional invention is
reserved. Although a very narrow claim may be presented herein, it should be
recognized the
scope of this invention is much broader than presented by the claim(s).
Broader claims may be
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submitted in an application that claims the benefit of priority from this
application.
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